Sound proofing system and method

ABSTRACT

A low-cost and easy to manufacture static structure and method for soundproofing walls, floors, and/or ceilings of rooms in new and/or existing construction utilizes an asphalt based flexible membrane as one or more sound absorbing layers which may be applied to an existing wall panel or first applied to one or more unmounted wall panels to form a laminated structure which is then affixed to the walls, floor or ceiling to be soundproofed. The wall panel is preferably gypsum wallboard. Each sound absorbing layer, in addition to soundproofing, may also serve to prevent or at least reduce air or water infiltration to and from the room.

FIELD OF THE INVENTION

This invention relates to interior building materials and methods, andmore particularly, to a novel soundproofing system and method.

BACKGROUND OF THE INVENTION

In new and existing construction, the interior floor, ceiling and sidewalls of a room are typically comprised of a plurality of spaced, loadbearing members, such as wall studs, and finishing materials, such asgypsum sheet material or plywood, affixed thereto. In many situations,it is desirable or necessary to provide the interiors of rooms of suchconstruction with sound and/or thermal insulation. The sound and/orthermal insulation should be low-cost, easy to manufacture and becapable of ready installation in new or existing construction. Theheretofore known soundproofing products and methods have beendisadvantageous in one or more of these and other aspects.

SUMMARY OF THE INVENTION

The present invention features a low-cost and easy to manufacture staticstructure for soundproofing interior walls, floors or ceilings of roomsin new and/or existing construction. Interior walls includes theinterior region of walls bounding the interior space in a structureincluding wood, concrete or other walls constructed of any other type ofmaterial. According to one embodiment, the present invention includescontiguous, sound absorbing material and wall layers adhesively joinedabout substantially coextensive confronting major faces. The soundabsorbing layer preferably comprises an asphalt based, flexible membranehaving opposing faces, at least one of which is self adhesive while thestructural layer is comprised of a sheet material having opposing majorfaces, with one of the opposing major surfaces of the sheet material ofthe wall structural layer substantially coextensive with and adhesivelyjoined to one of the major faces of the asphalt based, flexible membraneof the sound absorbing layer. In alternate embodiments, a silicon-basedrelease sheet may be releasably attached to the self-adhesive majorfaces of the asphalt based, flexible membrane of the sound absorbinglayer.

In any embodiment, the static structures for soundproofing interiorwalls according to the present invention are low in cost and easy tomanufacture, utilizing, for example, a readily available asphalt basedweatherproofing membrane as the sound absorbing flexible membrane layerand readily available gypsum board as the structural layer, and aresuitable for use in new or retrofit construction, by affixing, forexample, the static soundproofing structures of the present invention tostuds in new construction or to already existing wallboard duringretrofit. The sound-absorbing layer, in addition to soundproofing, alsoserves to prevent air infiltration or air from exiting the room. Thiscould reduce heating and air-conditioning bills, by making the room more“airtight.”

The method of soundproofing the interior walls of a room of the presentinvention comprises the steps of removing a release sheet to expose theself-adhesive surface of a flexible sound absorbing membrane; andadhering the exposed self-adhesive surface to a structural panel ofsheet material to provide a sound absorbing lamination. In retrofitconstruction, the structural panel may be a room interior wall panel,and in a next step another layer of wall panel may be affixed thereto.In a next step in new construction, the sound absorbing lamination isattached to the interior walls of the room to be soundproofed. Inaddition, in new construction, it is also contemplated that the methodmay comprise “sandwiching” a sheet of self-adhesive asphalt basedmaterial between two sheet of structural material, such as gypsumwallboard, and then affixing the three part laminated structure to afloor, wall or ceiling to be soundproofed.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other objects, inventive aspects and advantageous features ofthe present invention will become apparent as it becomes betterunderstood by reference to the following, solely exemplary, detaileddescription of the presently preferred embodiments, and to the drawings,wherein:

FIG. 1 is a partially broken away front pictorial view of a two-sidedsoundproofing membrane with release sheets on each side in accord withthe present invention;

FIG. 2 is a sectional view of the two-sided soundproofing membrane ofthe present invention;

FIG. 3 is a partially pictorial, partially schematic side view of oneembodiment of a soundproofing product in accord with the presentinvention; and

FIG. 4 is a partially pictorial, partially schematic side view ofanother embodiment of a soundproofing product in accord with the presentinvention.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

Referring now to FIG. 1, generally designated at 10 is a soundproofingmembrane in accord with the present invention. The soundproofingmembrane 10 is preferably flexible and constructed from an elastomericsheet 12, preferably asphalt based, which prevents sound transmissionfrom one side to the other. The soundproofing membrane may be flexibleor semi-flexible. In the case of a semi or less flexible membrane, theasphalt includes a high or higher filler content. Examples of “fillers”include talc (the preferred filler) and/or other inorganic fillers suchas barium sulfate, calcium carbonate or crushed minerals which serve toprovide “mass” to the membrane which slows the transmission of lowfrequency sound by 0-60%.

The layer 12 is “sticky” or self-adhesive on one or both sides. Eachself-adhesive side is covered with a silicon-based release sheet 14, 16(best seen in FIG. 2) that is substantially of the same size as thelayer 12. It has been found that the asphalt based flexible membranethat is commonly used as water- and weatherproofing typically on roofs,decks and other exterior roofing surfaces under roofing material isusable in accord with the present invention to provide soundproofing ofinterior walls. Any composition formula for the asphalt based flexiblemembrane may be employed, so long as it has enough “mass”, “pliability”or “elasticity” to serve as a sound absorbing and sound deadeningmaterial. If the material is too brittle, it will act like the remainderof the structure and transmit the sound instead of absorbing it.

In a first embodiment, the soundproofing membrane of the presentinvention may be supplied in sheet or roll form and may be applied byhomeowners or contractors to ceilings, floors or walls; either toexisting sheet material such as plywood or wallboard or alternatively,may be applied to sub-floor, studs or ceiling joists. Although thesoundproofing membrane of the present invention includes at least onesurface which is self-adhesive, this is not a limitation of the presentinvention since it may be nailed, stapled or otherwise fastened to aninterior surface to be soundproofed and both major planar surfaces maybe self-adhesive.

One embodiment of a soundproofing product or static structure of thepresent invention designated generally at 30 in FIG. 3 is shown attachedto an interior room wall 32 in new and/or existing construction. Thestatic soundproofing structure 30 attached to interior wall 32 includescontiguous, sound absorbing layer 34 and wall layer 36, adhesivelyjoined about substantially coextensive confronting major faces 38. Thesound absorbing layer 34 is preferably comprised of an asphalt based,flexible membrane having opposing self-adhesive faces, of the typedescribed above in connection with the description of FIGS. 1, 2. Thestructural layer 36 is preferably comprised of a gypsum based sheetmaterial having opposing major faces, such as sheetrock, or otherinterior wall laminate. The confronting major surfaces of the flexiblesound absorbing layer 34 and of the sheet material of the wallstructural layer 36 are adhesively joined together at their interface38.

In use, various modes or embodiments are contemplated. In a firstembodiment, the sound absorbing and soundproofing barrier membrane 34could be applied to the ceiling or wall panel 36, such as sheetrock, andthe assembly in turn adhered, nailed or screwed to the wall 32. In aretrofit situation, the contractor or homeowner could apply the membrane34 over the existing wallboard 32 on the wall or ceiling of the home,and then apply another layer of wallboard 36 over that. In yet anotherembodiment, the preconfigured structure 30 comprising wallboard 36 andsoundproofing layer 34 could be affixed to the interior room wall 32.

Another embodiment generally designated at 50 in FIG. 4 of asoundproofing product of the present invention is shown attached to aninterior wall 52 of a room in new and/or existing construction. Thestatic soundproofing (sound dampening) structure 50 attached to interiorwall 52 is similar to the embodiment 30 of FIG. 3, except that it is athree-layer product in which the sound absorbing layer 54 is“sandwiched” between contiguous wall layers 56, 58 adhesively joinedabout substantially coextensive confronting major faces at therespective interfaces 53, 55 there between. Structure 50 allows for theuse of fewer nails which are undesirable since the nails transmit sound.The sound absorbing layer 54 is preferably comprised of the same asphaltbased, flexible membrane having opposing self-adhesive faces of the typedescribed above in connection with the description of FIGS. 1, 2. Thestructural layers 56, 58 are each preferably comprised of gypsum basedsheet material, such as sheetrock, or other interior wall laminate,having opposing major faces.

In use, this embodiment contemplates that the entire sandwichedstructure 50 will be sold as an integral unit. This embodiment willtypically not be used in a retrofit situation although it is notprecluded from being used as such. It is contemplated that in thisembodiment, the homeowner or contractor would simply apply thesandwiched structure 50 to wall studs or ceiling joists 52 using nails,screws, adhesive or the like. In a retrofit situation, the contractor orhomeowner could apply the sandwiched structure 50 over the existingwallboard 52 on the wall or ceiling of the home.

The invention also has application in its product and its method aspectsfor flooring such as plywood sub floors prior to the installation of thefloor or another piece of plywood to serve as the base for otherflooring materials such as tile, linoleum or carpet. In addition toeliminating or at least greatly minimizing the transmission of sound,the present invention also serves to reduce air infiltration into andout of the room, thereby helping to conserve energy required to heat andcool a room. The present invention can also serve as a moisture barrier,i.e., bathroom floors.

The present invention is not intended to be limited to a system ormethod which must satisfy one or more of any stated or implied object orfeature of the invention and should not be limited to the preferred,exemplary, or primary embodiment(s) described herein. Modifications andsubstitutions by one of ordinary skill in the art are considered to bewithin the scope of the present invention, which is not to be limitedexcept by the allowed claims and their legal equivalents.

1. A soundproofing structure for interior walls, floors or ceilings ofrooms in new and/or existing construction, comprising: a contiguous,sound absorbing layer and structural layer adhesively joined aboutsubstantially coextensive confronting major faces of said soundabsorbing layer and said structural layer, said sound absorbing layercomprised of an asphalt based flexible membrane having opposing faces,at least one of said opposing faces of said asphalt based flexiblemembrane being self-adhesive, and wherein said structural layer iscomprised of sheet like material having opposing major faces, andwherein one of the opposing major surfaces of said structural layer issubstantially coextensive with and adhesively joined to said at leastone self-adhesive major face of said asphalt based flexible membrane. 2.The soundproofing structure of claim 1, wherein said asphalt basedflexible membrane includes two self-adhesive opposing faces, and furtherincluding a second structural layer attached to the other self-adhesiveopposing face of said asphalt based flexible membrane.
 3. Asoundproofing structure for interior walls, floors or ceilings of roomsin new and/or existing construction, comprising: a contiguous, soundabsorbing layer and structural layer adhesively joined aboutsubstantially coextensive confronting major faces of said soundabsorbing layer and said structural layer, said sound absorbing layercomprised of an asphalt based membrane having opposing faces, at leastone of said opposing faces of said asphalt based membrane beingself-adhesive, and wherein said structural layer is comprised of sheetlike material having opposing major faces, and wherein one of theopposing major surfaces of said structural layer is substantiallycoextensive with and adhesively joined to said at least oneself-adhesive major face of said asphalt based membrane.
 4. Thesoundproofing structure of claim 3, wherein said asphalt based membraneis a flexible membrane.
 5. The soundproofing structure of claim 3,wherein said asphalt based membrane is a semi-flexible membrane.
 6. Thesoundproofing structure of claim 5, wherein said semi-flexible asphaltmembrane includes a filler.
 7. The soundproofing structure of claim 6,wherein said filler includes an inorganic filler.
 8. The soundproofingstructure of claim 7, wherein said inorganic filler is selected from thegroup consisting of talc, barium sulfate, calcium carbonate, and crushedminerals.
 9. A method of soundproofing the interior walls of a roomcomprising the steps of: providing an asphalt based, sound absorbingmembrane having a release sheet on at least one surface; removing atleast a first release sheet to expose a self-adhesive surface of saidasphalt based, sound absorbing membrane; and adhering the exposedself-adhesive surface to a first sheet like structural panel, to providea sound absorbing lamination structure.
 10. The method of soundproofingthe interior walls of a room of claim 9, wherein said structural panelis an interior wall panel for a room.
 11. The method of soundproofingthe interior walls of a room of claim 9 wherein said structural panel isa sheet of gypsum wallboard.
 12. The method of soundproofing theinterior walls of a room of claim 9, wherein said provided asphaltbased, sound absorbing membrane includes a release sheet on first andsecond surfaces, and further including the act of applying another sheetlike structural panel to the second surface of said asphalt based, soundabsorbing membrane opposite said first surface adhered to said firstsheet like structural panel.
 13. The method of soundproofing theinterior walls of a room of claim 12, further including the step ofattaching said sound absorbing lamination onto the interior region of aroom to be soundproofed.
 14. The method of soundproofing the interiorwalls of a room of claim 9, wherein said asphalt based, sound absorbingmembrane includes a flexible, asphalt based, sound absorbing membrane.15. The soundproofing structure of claim 9, wherein said asphalt basedmembrane is a semi-flexible membrane.
 16. The soundproofing structure ofclaim 15, wherein said semi-flexible asphalt membrane includes a filler.17. The soundproofing structure of claim 16, wherein said fillerincludes an inorganic filler.
 18. The soundproofing structure of claim17, wherein said inorganic filler is selected from the group consistingof talc, barium sulfate, calcium carbonate, and crushed minerals.